Concrete Expansion Joint

ABSTRACT

A concrete expansion joint and seal assembly includes opposed generally planar side frame members with spaced apart flanges forming channels which are operable to bond the side frame members to opposed sections of concrete when the expansion joint is placed in its working position. A flexible seal member includes a loop portion and opposed legs coextruded with and bonded to edges of the side frame members. The side frame members are temporarily held contiguous with each other at their respective distal ends by adhesive tape, an adhesive or a hook portion formed on one of the side frame members for engaging the distal end of the other side frame member. The seal member is preferably formed of an extrudable thermoplastic elastomer and the side frame members are preferably formed of extrudable polypropylene.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 4,388,016 issued Jun. 14, 1983 to Bertram J. Levey is directed to an expansion joint and seal assembly for use with concrete structures. The type of expansion joint and seal assembly described in the Levey patent, which patent is incorporated herein by reference, functions properly as an expansion joint for concrete structures such as roadways, sidewalks, driveways, runways and other concrete structures.

Certain improvements have been sought in concrete expansion joints, particularly of the type described in the Levey patent. Such improvements include providing an expansion joint which is easy and economical to fabricate and does not require the complex structural features and assembly procedures required of the Levey expansion joint. There has also been a desire to provide an expansion joint which has an elastic memory which will allow the side frames or extension members to separate and remain connected to the respective sections of concrete to which they are adhered and to move back and forth with the separated sections of concrete while a seal is maintained therebetween. Still further, improvements have been sought in expansion joints of the general type described wherein the opposed side frames or extension members remain temporarily connected to each other, particularly at their adjacent distal ends, prior to placement in the concrete structure but at the same time are capable of separating from each other once in place and required to begin their function as part of an expansion joint.

Accordingly, in view of the problems associated with prior art expansion joints and the desire to provide the improvements indicated hereinabove, as well as other improvements deemed desirable in concrete expansion joints, the present invention has been developed.

SUMMARY OF THE INVENTION

The present invention provides an improved concrete expansion joint and seal assembly which is relatively uncomplicated, easily fabricated and forms a permanent seal between separated sections of concrete.

In accordance with one aspect of the present invention, a concrete expansion joint and the like is provided which is formed of opposed side frame or extension members which are interconnected by a seal member which is flexible, has an elastic memory and is prejoined to the side frame members by coextruding the seal member and the side frame members of suitable materials including preferably, a thermoplastic elastomer and polypropylene, respectively.

In accordance with another aspect of the present invention, a concrete expansion joint is provided which is coextruded with an elastic memory of a seal member so that the side frame or extension members are biased to remain connected to separated sections of concrete so that the expansion joint functions properly when the separated sections of concrete move toward and away from each other during normal expansion and contraction due to thermal conditions or changing soil conditions, for example. In this regard, the coextruded expansion joint assembly is provided with means for holding, at least temporarily, the side frame or extension members together so that the expansion joint may be inserted into poured concrete in accordance with normal practice for placing expansion joints in their working positions. The side frame or extension members may be secured together by a double sided adhesive tape member, by a relatively weak adhesive or by providing the adjacent side frame members with cooperating hook and latch portions whereby the side frame or extension members are at least temporarily tightly secured to each other and are substantially contiguous with each other for purposes of placing the expansion joint in its working position. The side frame members are substantially planar but may be formed with opposed shallow bowed or curvilinear portions to assure that their distal ends form a so-called knife edge or chisel point to facilitate insertion in poured concrete.

Those skilled in the art will further appreciate the above-mentioned advantages and superior features of the invention together with other important aspects thereof upon reading the detailed description which follows in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an expansion joint and seal assembly in accordance with the present invention;

FIG. 2 is a detail view of part of one of the side frame members of the expansion joint shown in FIG. 1 illustrating the placement of an adhesive tape adjacent a distal end thereof;

FIG. 3 is a transverse section view of an embodiment of the expansion joint of the present invention which includes an adhesive for temporarily securing the side frame members to each other at their distal ends;

FIG. 4 is a transverse section view of another embodiment of an expansion joint in accordance with the invention;

FIG. 5 is a view similar to FIG. 4 but showing the side frame members of the embodiment of FIG. 4 connected to each other;

FIG. 6 is a somewhat schematic view of the expansion joint embodiment shown in FIGS. 4 and 5 being coextruded; and

FIG. 7 is a somewhat schematic view showing an expansion joint in accordance with the present invention in its working position between two separated sections of concrete.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the description which follows like elements are marked throughout the specification and drawing with the same reference numerals, respectively. The drawings are not necessarily to scale and certain features may be shown in somewhat schematic or generalized form in the interest of clarity and conciseness.

Referring to FIG. 1, there is illustrated an expansion joint and seal assembly in accordance with one preferred embodiment of the invention and generally designated by the numeral 10. The expansion joint and seal assembly 10 is characterized by a resilient seal member 12 having a preformed loop portion 14 and opposed depending legs 16 and 18. The seal member 12 is preferably formed of an extruded thermoplastic elastomer (TPE) having a hardness of about 67 Shore A durometer, and may be one of a material sold under the trademarks Santoprene or Vyram, commercially available from Advanced Elastomer Systems, LP, Akron, Ohio. The seal member 12 is shown in assembly with a somewhat channel-shaped top cap 20 which is snap fitted over the loop portion 14 of the seal member and is removable therefrom in accordance with the teaching of U.S. Pat. No. 4,388,016.

Referring further to FIG. 1, the expansion joint and seal assembly 10 is further characterized by opposed generally planar side frame or extension members 22 and 24 which are disposed directly adjacent and contiguous with each other in the position shown in FIG. 1, which is the position of the assembly 10 when it is inserted in freshly poured concrete, again in accordance with the teaching of U.S. Pat. No. 4,388,016. However, unlike the expansion joint disclosed in U.S. Pat. No. 4,388,016, the side frame members 22 and 24 are permanently bonded to the seal member 12 by coextruding the seal member and the side frame members in a manner to be described generally hereinbelow. Side frame members 22 and 24 are preferably formed of extrudable polymer, such as polypropylene, polyethylene, polyester, polystyrene, polyvinyl chloride or Nylon.

Side frame member 22 includes a generally planar plate-like part 26 from which project spaced apart transverse flanges 28, 30 and 32, together with a somewhat chisel or knife blade-shaped flange part 34 defining the distal end of the side frame member 22. As illustrated throughout the drawings, the flanges 28 and 30 extend at acute angles from the plate part 26 and toward each other so as to define a channel 36. In like manner, the flange 32 and the somewhat chisel-shaped distal end part 34 also extend from the plate part 26 toward each other at acute angles to define a second channel 38. Accordingly, the channels 36 and 38 have inwardly turned or reentrant flange portions defining these channels so that when the side frame member 22 is immersed in flowable concrete it fills the channels and when such concrete hardens the side frame member are securely fastened thereto.

Side frame member 24 is substantially a mirror image of side frame member 22 and is characterized by a generally planar plate part 40 and spaced apart flanges 42, 44 and 46, together with a distal end chisel-shaped part 48 which is a mirror image of the chisel-shaped part 34. As with the side frame member 22, opposed channels 50 and 52 are defined by the flange portions 42 and 44 for flange 50 and flange portions 46 and chisel part 48 for the channel 52. Side frame members 22 and 24 have opposed, shallow, bowed or curvilinear parts 37 and 39 between the opposite ends of the side frame members to facilitate and maintain the side frame members tightly contiguous with each other at their distal ends to facilitate insertion in unhardened concrete or the like. Accordingly, the chisel-shaped parts 34 and 48 form a relatively fine chisel point or knife edge 56 which Facilitates insertion of the expansion joint and seal assembly 10 into freshly poured concrete, again generally in accordance with the teaching of U.S. Pat. No. 4,388,016. However, those skilled in the art will appreciate that the expansion joint and seal assembly 10 is advantageous in that by providing the side frame members 22 and 24 permanently bonded to the flexible seal member 12 at fabrication a more efficient and inexpensive assembly is provided in accordance with the method of manufacture and the bond between the side frame members 22 and 24 and the seal member 12 is strong and permanent thanks to the coextrusion of these three members.

Still further, the invention contemplates the provision of means for securing, at least temporarily, the side frame members 22 and 24 to each other, which means may comprise an elongated strip of double sided adhesive tape, generally designated by the numeral 54 in FIGS. 1 and 2. The strip of tape 54 may be of a type commercially available such as double sided foam tape sold under the trademark Dubl Kote and commercially available from Duraco, Inc. of Forest Park, Ill. Subsequent to extrusion of the expansion joint and seal assembly 10, comprising the members 12, 22 and 24, the strip of tape 54 may be applied to one or the other of the side frame members adjacent edge 56 of the joined side frame members to temporarily hold the side frame members substantially contiguous with each other, as illustrated in FIG. 1. Accordingly, since the seal member 12 may be created in a manner which tends to provide an elastic memory in the seal member, biasing the side frame members away from each other, see FIG. 4 for example, the joining means formed by the tape 54 maintains the side frame members contiguous with each other for purposes of insertion of the expansion joint and seal assembly 10 into poured concrete. However, once the concrete has set and is bonded and engaged with the side frame members 22 and 24, and as the concrete sections separate, the tape 54 will not be strong enough to prevent separation of the side frame members so that they may perform their intended function.

Referring briefly to FIG. 3, an alternate embodiment of the present invention is illustrated and generally designated by the numeral 10 a. The expansion joint and seal assembly 10 a is substantially like the expansion joint and seal assembly 10 except that, in place of the tape 54, one or both of facing surfaces of the distal ends of the side frame members 22 and 24 are coated with an adhesive 60 to secure the side frame members to each other for the same purpose contemplated for the embodiment described in conjunction with FIGS. 1 and 2. Otherwise, the expansion joint and seal assembly 10 a is like that illustrated and described hereinbefore in conjunction with FIGS. 1 and 2.

Referring now to FIGS. 4 and 5, another preferred embodiment in accordance with the invention is characterized as an expansion joint and seal assembly 10 b which includes the flexible seal member 12 coextruded and bonded to opposed side frame members 22 a and 24 a which include substantially planar plate parts 26 a and 40 a. The configuration of the expansion joint and seal assembly 10 b is such that a chisel-shaped part 34 a of the side frame member 22 a forms the edge 56 and is provided with a hook tip part 62 projecting from the chisel-shaped distal end part 34 a in a direction toward the side frame member 24 a and forming a hook throat 66. Hook part 62 is operable to receive a tip part 48 a of the side frame member 24 a. The dimensions of the side frame members 22 a and 24 a are slightly different such that the side frame member 24 a may be deflected slightly such that the chisel-shaped tip part 48 a nests in the recess or throat 66 provided by the hook 62, as illustrated in FIG. 5, after the expansion joint and seal assembly has been coextruded in the same manner as the embodiments of FIGS. 1 through 3. In all other respects the expansion joint and seal assembly 10 b is like the embodiments previously described.

However, since the side frame members 22 and 24, as well as the side frame members 22 a and 24 a are at least slightly flexible, once the expansion joint and seal assembly 10 b is placed in poured concrete, the concrete has filled the channel portions 36, 38, 50 and 52 and the concrete has hardened, then when the concrete sections separate, the side frame members 22 a and 24 a will become disconnected at their distal ends to remain connected to the separated concrete sections. After extrusion of the expansion joint and seal assembly 10 b, the side frame members are placed contiguous with each other, as illustrated in FIG. 5, until they are forced to separate when they are in their working positions.

As mentioned previously, the position of the side frame members 22 a and 24 a shown in FIG. 4 is the position that these members assume together with the position of the legs 16 and 18 of the seal member 12 when these members are coextruded. In this way, elastic memory is built into the loop portion 14 of the seal member which tends to bias the side frame members 22 a and 24 a to separate at least partially when they are in their working positions which aids these members to separate at their distal ends and to remain connected to separated concrete sections to allow the seal member to perform its intended function.

Referring briefly to FIG. 6, there is illustrated an extrusion device 70 which is shown in somewhat schematic form and which is operable to coextrude the seal member 12 and the side frame members 22 a and 24 a to form the expansion joint and seal assembly 10 b as illustrate. Conventional coextrusion equipment may be used to coextrude the component parts of the expansion joint and seal assemblies 10, 10 a and 10 b whereby these devices may be completely fabricated in essentially one major manufacturing step.

Referring briefly to FIG. 7, the expansion joint and seal assembly 10 a is shown in its working position wherein the assembly has been inserted into a concrete slab which has separated into two sections 80 and 82 and the removable cap 20 has been removed. As shown in FIG. 7, side frame members 22 and 24 are securely fastened to the concrete sections 80 and 82 and the seal member 12 flexed to maintain et seal between concrete sections to prevent the entry of water, snow or ice, for example.

Those skilled in the art will appreciate the advantages and superior features of the embodiments of the invention described herein. The methods of manufacture and use are believed to be readily understandable to those of ordinary skill in the art. Corrosion resistant and coextrudable materials may be used to fabricate the seal member 12 and the side frame members 22, 22 a, 24 and 24 a other than those described herein.

Although preferred embodiments have been described those skilled in the art will appreciate that substitutions and modifications may be made without departing from the scope and spirit of the appended claims. 

1-26. (canceled)
 27. A method of forming an expansion joint and seal assembly for a concrete structure comprising the steps of: providing extrudable material for forming said expansion joint and an extrudable material for forming said seal assembly; coextruding an expansion joint and a seal assembly through an extrusion die, wherein said expansion joint has a pair of elongated generally planar side frame members, each of said side frame members, including a substantially planar plate part and laterally projecting flanges forming channels for receiving concrete and for bonding said side frame members to adjacent sections of concrete, each of said side frame members including a distal end part, and a flexible seal member including a loop portion formed integral with opposed legs, said legs being joined to cooperating edges of said plate parts of said side frame members by coextrusion of said seal member with said side frame members; and applying securing means to at least one said side member for securing side members together.
 28. The method set forth in claim 27 wherein: the step of forming side frame members includes forming said side members from an extrudable polymer selected from a group consisting of polypropylene, polyethylene, polyester, polystyrene, poly-vinyl chloride and Nylon.
 29. The method set forth in claim 27 wherein: the step of coextruding said seal member includes forming said seal member from an extrudable material comprising a thermoplastic elastomer.
 30. The method set forth in claim 27 wherein: said step of coextruding said seal member includes forming said seal member from an extrudable material having an elastic memory for biasing said side frame members to separate from each other.
 31. The method set forth in claim 27 wherein: said step of applying a securing means to at least one said side member for securing side members together includes applying said means to said side frame members at their respective distal ends.
 32. The method set forth in claim 31 wherein: said step of applying a securing means comprises adhesive tape secured to said plate parts of said side frame members, respectively.
 33. The method set forth in claim 31 wherein: said step of applying a securing means comprises an adhesive applied to said plate part of at least one of said side frame members.
 34. The method set forth in claim 31 wherein: said step of coextruding comprises extruding said one of said side frame members to have a hook part for engaging a distal end of the other of said side frame members for securing said side frame members to each other.
 35. The method set forth in claim 27 wherein: said step of coextruding comprises extruding said side frame members having opposed outwardly bowed portions of said plate parts, respectively, for urging the distal ends of said side frame members to form a chisel or knife edge when contiguous with each other.
 36. A method of forming an expansion joint and seal assembly for a concrete structure comprising the steps of: providing an extrudable polymer selected from a group consisting of polypropylene, polyethylene, polyester, polystyrene, polyvinyl chloride and Nylon for forming a side frame member; providing an extrudable material comprising a thermoplastic elastomer for forming a seal member; coextruding said extrudable polymer and said an extrudable material comprising a thermoplastic elastomer to form an expansion joint, wherein said side frame member has a pair of elongated generally planar side frame members, each of said side frame members, including a substantially planar plate part and laterally projecting flanges forming channels for receiving concrete and for bonding said side frame members to adjacent sections of concrete, each of said side frame members including a distal end part, and said seal member includes a loop portion formed integral with opposed legs, said legs being joined to cooperating edges of said plate parts of said side frame members by coextrusion of said seal member with said side frame members; and releasably securing said side frame members to each other at their respective distal ends.
 37. The method set forth in claim 36 wherein: said step of coextruding said seal member includes forming said seal member from an extrudable material having an elastic memory for biasing said side frame members to separate from each other.
 38. The method set forth in claim 36 wherein: said step of applying a securing means comprises adhesive tape secured to said plate parts of said side frame members, respectively.
 39. The method set forth in claim 36 wherein: said step of applying a securing means comprises an adhesive applied to said plate part of at least one of said side frame members.
 40. The method set forth in claim 36 wherein: said step of coextruding comprises extruding said one of said side frame members to have a hook part for engaging a distal end of the other of said side frame members for securing said side frame members to each other.
 41. The method set forth in claim 36 wherein: said step of coextruding comprises extruding said side frame members having opposed outwardly bowed portions of said plate parts, respectively, for urging the distal ends of said side frame members to form a chisel or knife edge when contiguous with each other.
 42. A method of forming an expansion joint and seal assembly for a concrete structure comprising the steps of: providing an extrudable polymer selected from a group consisting of polypropylene, polyethylene, polyester, polystyrene, polyvinyl chloride and Nylon for forming a pair of elongated generally planar side frame members; providing an extrudable material comprising a thermoplastic elastomer for forming a seal member; coextruding said extrudable polymer and said an extrudable material comprising a thermoplastic elastomer to form an expansion joint, wherein said coextruded side frame members have a pair of elongated generally planar side frame members, each of said side frame members including a substantially planar plate part and laterally projecting flanges forming channels for bonding said side frame members to adjacent sections of concrete, each of said side frame members including a distal end part, said side frame members are formed with opposed outwardly bowed portions of said plate parts, respectively, for urging the distal ends of said side frame members to form a chisel edge when contiguous with each other, and said seal member including a loop portion formed integral with opposed legs, said legs being joined to cooperating edges of said plate parts of said side frame members by coextrusion of said seal member with said side frame members; and applying a releasable adhesive tape to temporarily secure said side frame members to each other at their respective plate parts, distal ends, or both. 